Heat exchanger assembly

Abstract

A heat exchanger assembly includes a first single-piece manifold and a second single-piece manifold spaced from and parallel to the first single-piece manifold. Each of the first and second single-piece manifolds has a tubular wall defining a flow path. A plurality of flow tubes extend in parallel between the first and second single-piece manifolds and are in fluid communication with the flow paths. An insert having a distribution surface is slidably disposed in the flow path of the first single-piece manifold to establish a distribution chamber within the first single-piece manifold. A series of orifices defined in the distribution surface of the insert are in fluid communication with the flow path and the distribution chamber for uniformly distributing a heat exchange fluid between the flow path and the flow tubes.

1 . A heat exchanger assembly comprising:
 a first single-piece manifold;   a second single-piece manifold spaced from and parallel to said first single-piece manifold;   each of said first and second single-piece manifolds having a tubular wall defining a flow path;   a plurality of flow tubes extending in parallel between said first and second single-piece manifolds and in fluid communication with said flow paths;   an insert having a distribution surface and slidably disposed in said flow path of said first single-piece manifold to establish a distribution chamber within said first single-piece manifold; and   a series of orifices defined in said distribution surface of said insert and in fluid communication with said flow path and said distribution chamber for uniformly distributing a heat exchange fluid between said flow path and said flow tubes.   
   
   
       2 . A heat exchanger assembly as set forth in  claim 1  wherein said orifices are in alignment with said flow tubes with one of said orifices aligned per at least one of said flow tubes. 
   
   
       3 . A heat exchanger assembly as set forth in  claim 1  wherein said flow tubes are grouped into a plurality of flow tube groups. 
   
   
       4 . A heat exchanger assembly as set forth in  claim 3  wherein said orifices are in alignment with said flow tube groups with one of said orifices aligned per at least one of said flow tube groups. 
   
   
       5 . A heat exchanger assembly as set forth in  claim 1  further comprising;
 a second insert having a distribution surface and slidably disposed in said flow path of one of said first and second single-piece manifolds to establish a distribution chamber within one of said first and second single-piece manifolds, and   a series of orifices defined in said distribution surface of said second insert and in fluid communication with said flow path and said distribution chamber for uniformly distributing a heat exchange fluid between said flow path and said flow tubes.   
   
   
       6 . A heat exchanger assembly as set forth in  claim 5  wherein said second insert is slidably disposed in said flow path of said first single-piece manifold along with said insert. 
   
   
       7 . A heat exchanger assembly as set forth in  claim 5  said second insert is slidably disposed in said flow path of said second single-piece manifold. 
   
   
       8 . A heat exchanger assembly as set forth in  claim 1  wherein said insert is removable from said flow path of said first single-piece manifold. 
   
   
       9 . A heat exchanger assembly as set forth in  claim 1  further comprising a width defined within said tubular wall of said first single-piece manifold, and at least one partial separator integrally extending from said distribution surface of said insert outwardly toward said tubular wall of said first single-piece manifold such that said partial separator obstructs a portion of said width of said first single-piece manifold for directing the heat exchange fluid to said orifices. 
   
   
       10 . A heat exchanger assembly as set forth in  claim 1  further comprising a width defined within said tubular wall of said first single-piece manifold, and at least one full separator integrally extending from said distribution surface of said insert outwardly toward and to said tubular wall of said first single-piece manifold such that said full separator obstructs an entirety of said width of said first single-piece manifold for directing the heat exchange fluid to said flow tubes. 
   
   
       11 . A heat exchanger assembly as set forth in  claim 1  further comprising a width defined within said tubular wall of said first single-piece manifold, and at least one partial baffle slidably disposed in said flow path and having a perimeter with only a portion of said perimeter contacting said tubular wall such that said at least one partial baffle obstructs a portion of said width of said first single-piece manifold for directing the heat exchange fluid to said orifices. 
   
   
       12 . A heat exchanger assembly as set forth in  claim 1  further comprising a width defined within said tubular wall of said first single-piece manifold, and at least one full baffle slidably disposed in said flow path and having a perimeter with an entirety of said perimeter contacting said tubular wall such that said at least one full baffle obstructs an entirety of said width of said first single-piece manifold for directing the heat exchange fluid to said flow tubes. 
   
   
       13 . A heat exchanger assembly as set forth in  claim 1  wherein each of said tubular walls of said first and second single-piece manifolds includes a pair of longitudinal ends adjacent and joined to each other such that each of said first and second single-piece manifolds are unitary. 
   
   
       14 . A heat exchanger assembly as set forth in  claim 1  wherein said first single-piece manifold includes a first tube end and a second tube end spaced from said first tube end, said flow path extends between said tube ends of said first single-piece manifold, and said heat exchanger assembly further comprises an axis extending centrally within said flow path of said first single-piece manifold, and a center plane intersecting said axis between said tubular wall of said first single-piece manifold. 
   
   
       15 . A heat exchanger assembly as set forth in  claim 14  wherein said distribution surface of said insert is spaced from and parallel to said center plane. 
   
   
       16 . A heat exchanger assembly as set forth in  claim 14  wherein said distribution surface of said insert includes a first insert end and a second insert end spaced from said first insert end and an insert length extending between said insert ends, and said insert length is equal to or less than said flow path of said first single-piece manifold. 
   
   
       17 . A heat exchanger assembly as set forth in  claim 14  wherein said distribution surface of said insert includes a first insert end and a second insert end spaced from said first insert end and an insert length extending between said insert ends, and said insert length is equal to or greater than said flow path of said first single-piece manifold. 
   
   
       18 . A heat exchanger assembly as set forth in  claim 14  further comprising a pair of side flanges extending opposite each other from said distribution surface of said insert toward and along said tubular wall of said first single-piece manifold for orienting and securing said insert in said flow path of said first single-piece manifold. 
   
   
       19 . A heat exchanger assembly as set forth in  claim 18  wherein said side flanges are curved and said tubular wall is complimentary curved such that said side flanges mechanically engage said tubular wall. 
   
   
       20 . A heat exchanger assembly as set forth in  claim 19  wherein each of said side flanges extend from said distribution surface along said tubular wall toward and across said center plane for orienting and securing said insert in said flow path of said first single-piece manifold. 
   
   
       21 . A heat exchanger assembly as set forth in  claim 18  wherein said tubular wall of said first single-piece manifold defines at least two indentations with each indentation spaced from and opposite the other with said side flanges mechanically engaging said at least two indentations for orienting and securing said insert in said flow path of said first single-piece manifold. 
   
   
       22 . A heat exchanger assembly as set forth in  claim 18  further comprising a pair of tips with each tip spaced from and opposite the other with one of said tips curving to extend from one of said side flanges parallel to said distribution surface of said insert and the other of said tips curving to extend from the other of said side flanges parallel to said distribution surface of said insert. 
   
   
       23 . A heat exchanger assembly as set forth in  claim 22  wherein said flow tubes extend toward said center plane and mechanically engage said tips of said insert. 
   
   
       24 . A heat exchanger assembly as set forth in  claim 14  further comprising a center line parallel to said axis extending along said distribution surface of said insert. 
   
   
       25 . A heat exchanger assembly as set forth in  claim 24  wherein said orifices are spaced from each other and from said center line of said distribution surface of said insert. 
   
   
       26 . A heat exchanger assembly as set forth in  claim 24  wherein said orifices are spaced from each other along said center line of said distribution surface of said insert. 
   
   
       27 . A heat exchanger assembly as set forth in  claim 26  wherein said orifices are equally spaced from each other along said center line of said distribution surface of said insert. 
   
   
       28 . A heat exchanger assembly as set forth in  claim 24  wherein a portion of said distribution surface is concave and forms a groove therein bounded by a bottom surface spaced from said tubular wall of said first single-piece manifold. 
   
   
       29 . A heat exchanger assembly as set forth in  claim 28  wherein said orifices are defined in said bottom surface along said groove of said distribution surface of said insert. 
   
   
       30 . A heat exchanger assembly as set forth in  claim 29  wherein said groove is defined along said center line of said distribution surface of said insert. 
   
   
       31 . A heat exchanger assembly as set forth in  claim 29  wherein said groove is offset from said center line of said distribution surface of said insert. 
   
   
       32 . A heat exchanger assembly as set forth in  claim 1  wherein said first single-piece manifold defines at least one port in fluid communication with at least one of said flow path and said distribution chamber, and at least one coupler disposed in said at least one port and in fluid communication with at least one of said flow path and said distribution chamber through said at least one port for coupling an external tube to said first single-piece manifold. 
   
   
       33 . A heat exchanger assembly as set forth in  claim 32  wherein said first single-piece manifold includes a first tube end and a second tube end spaced from said first tube end, and further comprising an end cap disposed adjacent said first tube end wherein said at least one port is defined by said end cap.